I was right. Using a burr grinder I removed old damaged fiberglass all the way down to bright metal. The fiberglass was feathered back so that the repair would cover a large area. The larger the area the stronger the repair.
The green primer was removed before applying the Bondo. Bondo is intended to be applied directly over fiberglass and metal, not primer.
After the fiberglass resin and the Bondo cured, the area was block sanded until smooth. The next time we work in this area it will be for fresh primer.
Ty was able to come over for a couple hours today. Ty used the same basic technique on the front of the passenger door. After sanding, the thickest amount of filler material is estimated at only 1/32".
The passenger door is 2/3 done. As we continue to finish the car we will have less and less primer. You can gauge our progress by watching the primer disappear.
So how did we do on our first day of finish work? Ty and I think we did pretty good. Double click on the picture to judge for yourself.
After cleaning up the mess we took a few minutes to admire the car. There is shop talk about a white racing stripe. What do you think?